READ THIS FIRST. For questions or help with this product contact Tech Support at (570) or

Transcription

1 READ THIS FIRST Model G0759 ***IMPORTANT UPDATE*** For Machines Mfd. Since 05/16 and Owner's Manual Revised 07/15 For questions or help with this product contact Tech Support at (570) or The following change was recently made to this machine since the owner's manual was printed: Removed wire between spindle direction knob and circuit board (see Figure 1), making speed range identical in forward and reverse. Refer to updated wiring diagram on following page. Aside from this information, all other content in the owner's manual applies and MUST be read and understood for your own safety. IMPORTANT: Keep this update with the owner's manual for future reference. For questions or help, contact our Tech Support at (570) or B IN N IN A Circuit Board CESX N1 G L1 Gnd Motor Brushes L 110V Motor Wire Removed RPM Display ZD-SX-THL Gnd A On/Off Switch Kedu KJD-178/120V Spindle Direction Knob Kedu EN61058 Spindle Speed Knob WX14-12 Figure 1. Location of wire removed. COPYRIGHT MAY, 2016 BY GRIZZLY INDUSTRIAL, INC. WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC. #BL18227 PRINTED IN CHINA

2 Wiring Diagram Revised P3 P1 P2 A+ See Figure 61 Circuit Board JD-014 5WR02J A Fuse F10AL250V 10A L1 L2 Fuse F15AL250V 15A Neutral Hot Ground See Figure 62 Chip Guard Limit Switch 110 VAC 5-15 Plug Spindle RPM Sensor B A IN N See IN Figure 64 Circuit Board CESX N1 G L1 Gnd Motor Brushes L 110V Motor RPM Display ZD-SX-THL Gnd A On/Off Switch Kedu KJD-178/120V Spindle Direction Knob Kedu EN61058 Spindle Speed Knob WX G0759 Update (Mfd. Since 5/16)

3 MODEL G0759 MILL/DRILL w/stand & DRO MANUAL INSERT The Model G0759 is the same machine as the Model G0704 except the Model G0759 has a 3-axis DRO. Besides the differences noted in this insert, all other content in the Model G0704 owner's manual applies to this machine. Before operating your new machine, you MUST read and understand this insert, the entire Model G0704 manual, and the DRO manual to reduce the risk of injury when using this machine. If you have any further questions about this manual insert or the differences between the Model G0759 and the Model G0704, contact our Technical Support at (570) or techsupport@grizzly.com. COPYRIGHT FEBRUARY, 2014 BY GRIZZLY INDUSTRIAL, INC., REVISED APRIL, 2014 (TS) WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC. (FOR MODELS MANUFACTURED SINCE 1/14) #TS16276 PRINTED IN CHINA

4 MACHINE DATA SHEET Customer Service #: (570) To Order Call: (800) Fax #: (800) MODEL G0759 MILL/DRILL WITH STAND AND DRO Product Dimensions: Weight lbs. Width (side-to-side) x Depth (front-to-back) x Height x 24 x 31 in. Footprint (Length x Width) /4 x 16-1/2 in. Space Required for Full Range of Movement (Width x Depth) x 25 in. Shipping Dimensions: Carton #1 Type... Wood Crate Content... Machine Weight lbs. Length x Width x Height x 28 x 36 in. Carton #2 Type... Cardboard Box Content... Stand Weight lbs. Length x Width x Height x 17 x 33 in. Electrical: Motors: Main Power Requirement V, Single-Phase, 60 Hz Prewired Voltage V Full-Load Current Rating... 12A Minimum Circuit Size... 15A Connection Type... Cord & Plug Power Cord Included... Yes Power Cord Length... 6 ft. Power Cord Gauge AWG Plug Included... Yes Included Plug Type Switch Type... ON/OFF Push Button Horsepower... 1 HP Phase... Single-Phase Amps... 12A Speed RPM Type... Universal Power Transfer... Gear Drive Bearings... Shielded & Permanently Lubricated -2- Model G0759 (Mfd. Since 1/14)

5 Main Specifications: Operation Info Table Info Spindle Travel... 2 in. Max Distance Spindle to Column /2 in. Max Distance Spindle to Table in. Longitudinal Table Travel (X-Axis) /8 in. Cross Table Travel (Y-Axis) /2 in. Vertical Head Travel (Z-Axis) in. Head Tilt (Left/Right)... Left 90, Right 90 deg. Drilling Capacity for Cast Iron... 3/4 in. Drilling Capacity for Steel... 5/8 in. End Milling Capacity... 3/4 in Face Milling Capacity /2 in. Table Length /8 in. Table Width /16 in. Table Thickness /4 in. Number of T-Slots... 3 T-Slot Size... 7/16 in. T-Slots Centers /2 in. Spindle Info Spindle Taper... R-8 Number of Vertical Spindle Speeds... Variable Range of Vertical Spindle Speeds RPM Quill Diameter in. Drawbar Thread Size... 7/16-20 Drawbar Length /16 in. Spindle Bearings... Tapered Roller Bearings Construction Spindle Housing/Quill... Cast Iron Table... Precision-Ground Cast Iron Head... Cast Iron Column/Base... Cast Iron Base... Cast Iron Stand... Steel Paint Type/Finish... Enamel Other Specifications: Features: Country of Origin... China Warranty... 1 Year Approximate Assembly & Setup Time... 1 Hour Serial Number Location... ID Label on Head Casting Sound Rating db. ISO 9001 Factory... Yes Certified by a Nationally Recognized Testing Laboratory (NRTL)... No Digital spindle scale reads metric, inches, zero, set, on/off Forward/reverse switch Chip guard Digital display for spindle speed Dovetail column Front-Mounted fine feed knob Coolant trough Model G0759 (Mfd. Since 1/14) -3-

6 Column & Stand Please Note: We do our best to stock replacement parts whenever possible, but we cannot guarantee that all parts shown here are available for purchase. Call (800) or visit our online parts store at to check for availability. -4- Model G0759 (Mfd. Since 1/14)

7 Column & Stand REF PART # DESCRIPTION REF PART # DESCRIPTION 1 P Z-AXIS SLIDE 43 P Z-AXIS HANDWHEEL SHAFT 2 P SET SCREW M6-1 X P KEY 4 X 4 X 12 3 P FLAT WASHER 8MM 45 P PILLOW BLOCK 4 P LOCK WASHER 8MM 46 P SPACER 5 P CAP SCREW M X P PINION GEAR 6 P FLAT WASHER 12MM 48 P COLUMN 7 P LOCK WASHER 12MM 49 P Z-AXIS SCALE 8 P CAP SCREW M X P THREADED SLEEVE M6-1 X 16 9 P T-BOLT M P CAP SCREW M6-1 X P FLAT WASHER 10MM 52 P X-AXIS LEADSCREW BRACKET (LH) 11 P LOCK WASHER 10MM 54 P TABLE 12 P HEX NUT M P COOLANT HOSE FITTING 13 P SLIDE ALIGNMENT BLOCK 56 P X-AXIS LEADSCREW BRACKET (RH) 14 P LOCK PLUNGER, BRASS 57 P TABLE HANDWHEEL HANDLE M6-1 X P ADJUSTABLE HANDLE M6-1 X P TABLE HANDWHEEL 16 P GIB ADJUSTMENT SCREW 59 P TABLE GRADUATED DIAL 17 P Z-AXIS GIB 60 P THRUST BEARING P HEADSTOCK ANGLE SCALE 61 P CAP SCREW M6-1 X P CAP SCREW M5-.8 X P LIMIT STOP 20 P Z-AXIS WAY COVER 63 P T-NUT M P HEX NUT M P X-AXIS SCALE 22 P Z-AXIS WAY COVER BRACKET 65 P X-AXIS LEADSCREW 23 P Y-AXIS WAY COVER 66 P X-AXIS LEADSCREW NUT 24 P Y-AXIS WAY COVER BRACKET 67 P CAP SCREW M4-.7 X P Z-AXIS LEADSCREW LOCK NUT 68 P SADDLE 26 P THRUST BEARING P TABLE STOP BLOCK 27 P BEVEL GEAR 70 P Y-AXIS GIB 28 P KEY 4 X 4 X P Y-AXIS LEADSCREW NUT 29 P Z-AXIS LEADSCREW 72 P X-AXIS GIB 30 P Z-AXIS LEADSCREW NUT 73 P CAP SCREW M6-1 X P CAP SCREW M5-.8 X P X-AXIS BEARING HOUSING 31-1 P FLAT WASHER 5MM 75 P X-AXIS LEADSCREW 32 P BEARING COVER 76 P BASE 33 P CAP SCREW M X P CAP SCREW M X P COLUMN TOP PLATE 100 P STAND ASSEMBLY 35 P COLLAR FLANGE P STAND CABINET 36 P CAP SCREW M5-.8 X P STAND DOOR 37 P Z-AXIS GRADUATED DIAL P STAND DOOR LATCH 38 P Z-AXIS HANDWHEEL 412 P X/Z-AXIS DRO ASSEMBLY 39 P HANDWHEEL CURVED PLATE SPRING P DRO DISPLAY 40 P HEX NUT M P X-AXIS DRO SCALE 41 P Z-AXIS HANDWHEEL HANDLE M6-1 X P Y-AXIS DRO SCALE 42 P BALL BEARING 6001ZZ P Z-AXIS DRO SCALE Model G0759 (Mfd. Since 1/14) -5-

8 Electrical Box REF PART # DESCRIPTION REF PART # DESCRIPTION 78 P CIRCUIT BOARD JD-014 5WR02J 88 P ELECTRICAL BOX 79 P POTENTIOMETER W/ KNOB WX P CAP SCREW M5-.8 X 8 80 P CAP SCREW M3-.5 X P ELECTRICAL BOX REAR COVER 80-1 P HEX NUT M P FUSE HOLDER 81 P CIRCUIT BOARD CESX P FUSE 15A 250V FAST-ACTING, GLASS 83 P ON/OFF SWITCH KEDU KJD-178/120V 93 P POWER CORD 18G 3W 72" P CAP SCREW M4-.7 X P STRAIN RELIEF M20 X 1.5 TYPE-3 85 P CONTROL PANEL PLATE 95 P FWD/REV SWITCH KEDU EN P CAP SCREW M4-.7 X 6 96 P FUSE 10A 250V FAST-ACTING, GLASS 87 P RPM DIGITAL DISPLAY ZD-SX-THL -6- Model G0759 (Mfd. Since 1/14)

9 Headstock Model G0759 (Mfd. Since 1/14) -7-

10 Headstock REF PART # DESCRIPTION REF PART # DESCRIPTION 201 P QUILL RETAINING CLIP 243 P HANDWHEEL CURVED PLATE SPRING 202 P BUSHING 244 P FINE DOWNFEED GRADUATED DIAL 203 P COMPRESSION SPRING 245 P WORM SHAFT 204 P EXT RETAINING RING 45MM P DRAWBAR 7/16-20 x 9-11/ P BALL BEARING 6209ZZ P DRAWBAR RETAINER CAP 206 P COMBO GEAR 60/70T 246 P SPINDLE R P SPINDLE RING 16MM 247 P SPINDLE RING P CAP SCREW M3-.5 X P TAPERED ROLLER BEARING P ANGULAR CONTACT BEARING RS 249 P QUILL 208 P EXT RETAINING RING 15MM 250 P QUILL SEAL, RUBBER (UPPER) 209 P GEAR 37T 251 P PRELOAD ADJUSTER NUT P GEAR GUARD 252 P ADJUSTER SCREW M5-.8 X P CAP SCREW M3-.5 X P DOWEL PIN 6 X P EXT RETAINING RING 32MM 255 P DOWNFEED LEVER M X P BALL BEARING 6002ZZ P DOWNFEED LEVER GRIP M P COMBO GEAR 42/62T 256 P KNOB BOLT M X P SHAFT 257 P COARSE DOWNFEED HUB 214 P KEY 5 X 5 X P DOWNFEED GRADUATED DIAL 215 P KEY 5 X 5 X P COMPRESSION SPRING 216 P FORK 260 P CAP SCREW M4-.7 X P FORK ARM 261 P DOWNFEED FLANGE 218 P SET SCREW M5-.8 X P BUSHING 219 P DRAWBAR CAP 263 P WORM GEAR 220 P MOTOR COVER V P KEY 4 X 4 X P MOTOR 750W 110VDC 265 P GEAR SHAFT 16T P CARBON BRUSH 2-PC SET 266 P RIVET 2 X 5MM NAMEPLATE, STEEL P CARBON BRUSH CAP 1-PC 267 P HI/LO INDICATOR PLATE 222 P FLAT WASHER 4MM 268 P SET SCREW M X P CAP SCREW M4-.7 X P COMPRESSION SPRING 224 P CAP SCREW M6-1 X P STEEL BALL 6.5MM 225 P SPEED SENSOR BRACKET 271 P HI/LO HANDWHEEL P SPEED SENSOR CORD 272 P SET SCREW M5-.8 X P CAP SCREW M3-.5 X P SPEED KNOB PLATE 226 P SPEED SENSOR 274 P FORK SHAFT FLANGE 227 P MOTOR MOUNT 275 P FORK SHAFT 228 P CAP SCREW M5-.8 X P CAP SCREW M3-.5 X P MOTOR GEAR RING 292 P SPINDLE PIN 230 P GEAR 20T 293 P DRILL CHUCK ARBOR R8 X B P KEY 4 X 4 X P DRILL CHUCK B MM 232 P SET SCREW M5-.8 X P DRILL CHUCK KEY 1/4" STD 11T SD-3/4" 233 P CAP SCREW M3-.5 X P TAPERED ROLLER BEARING P Z-AXIS DRO ASSEMBLY 401 P HEX WRENCH 6MM P Z-AXIS DRO BRACKET 402 P HEX WRENCH 5MM P CAP SCREW M4-.7 X P HEX WRENCH 4MM 235 P Z-AXIS DRO SLIDE MOUNT 404 P HEX WRENCH 3MM 236 P ADJUSTABLE HANDLE M X P HEX WRENCH 2MM 237 P LOCK PLUNGER, BRASS 406 P WRENCH 8 X 10MM OPEN-ENDS 238 P HEADSTOCK CASTING 407 P WRENCH 17 X 19MM OPEN-ENDS 239 P HEADSTOCK REAR COVER 408 P SCREWDRIVER FLAT #2 240 P CAP SCREW M4-.7 X P SCREWDRIVER PHILLIPS #2 241 P FINE FEED KNOB 410 P BOTTLE FOR OIL 242 P HEADSTOCK FRONT COVER 411 P TOOLBOX -8- Model G0759 (Mfd. Since 1/14)

11 Chip Guard REF PART # DESCRIPTION REF PART # DESCRIPTION 277 P FLAT WASHER 3MM 284 P LIMIT SWITCH DATER KW P HEX NUT M P PROTECTIVE PAPER 279 P CAP SCREW M4-.7 X P SET SCREW M5-.8 X P EXT RETAINING RING 12MM 287 P CHIP GUARD POST 281 P WAVY WASHER 20MM 288 P CHIP GUARD 282 P GUARD MOUNTING BLOCK 289 P CAP SCREW M4-.7 X P LIMIT SWITCH L-BRACKET, COPPER 297 P CAP SCREW M3-.5 X 16 Model G0759 (Mfd. Since 1/14) -9-

12 Labels REF PART # DESCRIPTION REF PART # DESCRIPTION 301 P READ MANUAL LABEL 307 P GRIZZLY GREEN TOUCH-UP PAINT 302 P SAFETY GLASSES LABEL 308 P CUTTER WARNING LABEL 303 P MACHINE ID LABEL 309 P ENTANGLEMENT LABEL 304 P HIGH/LOW SPEED LABEL 310 P AVOID OVERHEATING LABEL 305 P GRIZZLY PUTTY TOUCH-UP PAINT 311 P GRIZZLY.COM LABEL 306 P MODEL NUMBER LABEL 312 P ELECTRICITY LABEL Safety labels help reduce the risk of serious injury caused by machine hazards. If any label comes off or becomes unreadable, the owner of this machine MUST replace it in the original location before resuming operations. For replacements, contact (800) or Model G0759 (Mfd. Since 1/14)

13 READ THIS FIRST Model G0704 ***IMPORTANT UPDATE*** For Machines Mfd. Since 05/16 and Owner's Manual Revised 07/15 For questions or help with this product contact Tech Support at (570) or The following change was recently made to this machine since the owner's manual was printed: Removed wire between spindle direction knob and circuit board (see Figure 1), making speed range identical in forward and reverse. Refer to updated wiring diagram on following page. Aside from this information, all other content in the owner's manual applies and MUST be read and understood for your own safety. IMPORTANT: Keep this update with the owner's manual for future reference. For questions or help, contact our Tech Support at (570) or B IN N IN A Circuit Board CESX N1 G L1 Gnd Motor Brushes L 110V Motor Wire Removed RPM Display ZD-SX-THL Gnd A On/Off Switch Kedu KJD-178/120V Spindle Direction Knob Kedu EN61058 Spindle Speed Knob WX14-12 Figure 1. Location of wire removed. COPYRIGHT MAY, 2016 BY GRIZZLY INDUSTRIAL, INC. WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC. #BL18226 PRINTED IN CHINA

14 Wiring Diagram Revised P3 P1 P2 A+ See Figure 61 Circuit Board JD-014 5WR02J A Fuse F10AL250V 10A L1 L2 Fuse F15AL250V 15A Neutral Hot Ground See Figure?? Chip Guard Limit Switch 110 VAC 5-15 Plug Spindle RPM Sensor B A IN N See IN Figure 64 Circuit Board CESX N1 G L1 Gnd Motor Brushes L 110V Motor RPM Display ZD-SX-THL Gnd A On/Off Switch Kedu KJD-178/120V Spindle Direction Knob Kedu EN61058 Spindle Speed Knob WX G0704 Update (Mfd. Since 5/16)

15 MODEL G0704 MILL/DRILL WITH STAND OWNER'S MANUAL (For models manufactured since 04/13) COPYRIGHT FEBRUARY, 2010 BY GRIZZLY INDUSTRIAL, INC. REVISED JULY, 2015 (BL) WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC. #JB12468 PRINTED IN CHINA

16 This manual provides critical safety instructions on the proper setup, operation, maintenance, and service of this machine/tool. Save this document, refer to it often, and use it to instruct other operators. Failure to read, understand and follow the instructions in this manual may result in fire or serious personal injury including amputation, electrocution, or death. The owner of this machine/tool is solely responsible for its safe use. This responsibility includes but is not limited to proper installation in a safe environment, personnel training and usage authorization, proper inspection and maintenance, manual availability and comprehension, application of safety devices, cutting/sanding/grinding tool integrity, and the usage of personal protective equipment. The manufacturer will not be held liable for injury or property damage from negligence, improper training, machine modifications or misuse. Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: Lead from lead-based paints. Crystalline silica from bricks, cement and other masonry products. Arsenic and chromium from chemically-treated lumber. Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: Work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

17 INTRODUCTION... 2 Manual Accuracy... 2 Contact Info... 2 Machine Description... 2 Identification... 3 Electronic Controls Identification... 4 Machine Data Sheet... 5 SECTION 1: SAFETY... 8 Safety Instructions for Machinery... 8 Additional Safety for Mill/Drills SECTION 2: POWER SUPPLY SECTION 3: SETUP Needed for Setup Unpacking Inventory Cleanup Site Considerations Moving & Placing Machine Mounting to Shop Floor Assembly Drill Chuck Arbor Test Run Spindle Break-In SECTION 4: OPERATIONS Operation Overview Basic Controls Digital Readout Unit Calculating Spindle Speed Spindle Speed and Direction Spindle Height Controls Drill Chuck Loading Tooling Headstock Travel (Z-Axis and Rotation) Table Travel Table of Contents SECTION 5: ACCESSORIES SECTION 6: MAINTENANCE Schedule Lubrication SECTION 7: SERVICE Troubleshooting Gibs Leadscrew Backlash Digital Readout Unit Battery Replacement Motor Service SECTION 8: WIRING Wiring Safety Instructions Wiring Diagram Electrical Components SECTION 9: PARTS Column Breakdown Column Parts List Electrical Box Breakdown & Parts List Headstock Breakdown Headstock Parts List Chip Guard Breakdown & Parts List Labels Breakdown & Parts List WARRANTY AND RETURNS... 57

18 INTRODUCTION Manual Accuracy Contact Info We are proud to offer this manual with your new machine! We've made every effort to be exact with the instructions, specifications, drawings, and photographs of the machine we used when writing this manual. However, sometimes we still make an occasional mistake. Also, owing to our policy of continuous improvement, your machine may not exactly match the manual. If you find this to be the case, and the difference between the manual and machine leaves you in doubt, check our website for the latest manual update or call technical support for help. Before calling, find the manufacture date of your machine by looking at the date stamped into the machine ID label (see below). This will help us determine if the manual version you received matches the manufacture date of your machine. Manufacture Date of Your Machine For your convenience, we post all available manuals and manual updates for free on our website at Any updates to your model of machine will be reflected in these documents as soon as they are complete. We stand behind our machines. If you have any questions or need help, use the information below to contact us. Before contacting, please get the serial number and manufacture date of your machine. This will help us help you faster. Grizzly Technical Support 1203 Lycoming Mall Circle Muncy, PA Phone: (570) We want your feedback on this manual. What did you like about it? Where could it be improved? Please take a few minutes to give us feedback. Grizzly Documentation Manager P.O. Box 2069 Bellingham, WA manuals@grizzly.com Machine Description The mill/drill is used to shape metal and solid workpieces by removing material with the use of a rotating cutting tool. In milling operations, the cutting tool remains stationary while the workpiece is drawn across it by moving the table. In drilling operations, the workpiece is held stationary on the table while the cutting tool moves up-and-down with the movement of the spindle and head. -2- Model G0704 (Mfd. Since 04/13)

19 Identification A B Y C W X D E V D F U T S R Q G H H P I O K K I J L N M Figure 1. G0704 Identification. A. Drawbar Cap and Drawbar B. Vertical (Z-Axis) Handwheel C. Speed Range Selector Knob D. Vertical Travel Lock E. Fine Feed Lock Knob F. Quill Feed Lever G. Table H. Longitudinal (X-Axis) Handwheel I. Longitudinal Table Stop J. Table Cross Travel Locks K. Table Longitudinal Travel Lock L. Table Center Stop M. Machine Stand Model G0704 (Mfd. Since 04/13) N. Storage Access Door O. Cross (Y-Axis) Handwheel P. Longitudinal Scalev Q. Drill Chuck R. Headstock Tilt Scale S. Chip Guard T. Quill Lock Lever U. Fine Feed Knob V. Digital Readout (Page 4) W. Control Panel (Page 4) X. Headstock Y. Column -3-

20 Electronic Controls Identification A K B J I H G F C D E Figure 2. G0704 electronic controls identification. A. Spindle RPM Readout B. Spindle Digital Readout Power Button C. Digital Readout ZERO Button D. Digital Readout Battery Cover & Battery E. Spindle Depth Display DECREASE Button F. Spindle Depth Display INCREASE Button G. IN/MM Unit Selection Button H. Spindle Depth Display I. Spindle Direction Selection Knob J. Variable Spindle Speed Knob K. START/Emergency Stop Buttons -4- Model G0704 (Mfd. Since 04/13)

21 MACHINE DATA SHEET Customer Service #: (570) To Order Call: (800) Fax #: (800) Product Dimensions: MODEL G0704 DRILL/MILL WITH STAND Weight lbs. Width (side-to-side) x Depth (front-to-back) x Height x 24 x 31 in. Footprint (Length x Width) /4 x 16-1/2 in. Space Required for Full Range of Movement (Width x Depth) x 25 in. Shipping Dimensions: Carton #1 Type... Wood Crate Content... Machine Weight lbs. Length x Width x Height x 28 x 36 in. Carton #2 Type... Cardboard Box Content... Stand Weight lbs. Length x Width x Height x 17 x 33 in. Electrical: Motors: Main Power Requirement V, Single-Phase, 60 Hz Prewired Voltage V Full-Load Current Rating... 12A Minimum Circuit Size... 15A Connection Type... Cord & Plug Power Cord Included... Yes Power Cord Length... 6 ft. Power Cord Gauge AWG Plug Included... Yes Included Plug Type Switch Type... ON/OFF Push Button Switch w/safety Cover Type... Universal Horsepower... 1 HP Phase... Single-Phase Amps... 12A Speed RPM Power Transfer... Gear Drive Bearings... Shielded & Permanently Lubricated Model G0704 (Mfd. Since 04/13) -5-

22 Main Specifications: Operation Info Table Info Spindle Travel... 2 in. Max Distance Spindle to Column /2 in. Max Distance Spindle to Table in. Longitudinal Table Travel (X-Axis) /8 in. Cross Table Travel (Y-Axis) /8 in. Vertical Head Travel (Z-Axis) in. Head Tilt (Left/Right) deg. Drilling Capacity for Cast Iron... 3/4 in. Drilling Capacity for Steel... 5/8 in. End Milling Capacity... 3/4 in. Face Milling Capacity /2 in. Table Length /8 in. Table Width /16 in. Table Thickness /4 in. Number of T-Slots... 3 T-Slot Size... 7/16 in. T-Slots Centers /2 in. Spindle Info Spindle Taper... R-8 Number of Vertical Spindle Speeds... Variable Range of Vertical Spindle Speeds RPM Quill Diameter in. Drawbar Thread Size... 7/16-20 Drawbar Length /16 in. Spindle Bearings... Tapered Roller Bearings Construction Spindle Housing/Quill... Cast Iron Table... Precision-Ground Cast Iron Head... Cast Iron Column/Base... Cast Iron Base... Cast Iron Stand... Steel Paint Type/Finish... Enamel Other Specifications: Features: Country of Origin... China Warranty... 1 Year Approximate Assembly & Setup Time... 1 Hour Serial Number Location... ID Label on Head Casting Sound Rating db ISO 9001 Factory... Yes CSA, ETL, or UL Certified/Listed... No Digital spindle scale reads metric, inches, zero, set, on/off Forward/reverse switch Chip guard Digital display for spindle speed Dovetail column Front mounted fine feed knob Coolant trough -6- Model G0704 (Mfd. Since 04/13)

23 Accessories Included: Drill chuck 3 16mm with B16 taper Drill chuck arbor B16 x R8 Two T-bolts Two open-ended combo wrenches Chuck key Oil bottle Extra fuse Hex wrenches Standard and Phillips screwdrivers Tool box Model G0704 (Mfd. Since 04/13) -7-

24 For Your Own Safety, Read Instruction Manual Before Operating This Machine The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words intended to convey the level of importance of the safety messages. The progression of symbols is described below. Remember that safety messages by themselves do not eliminate danger and are not a substitute for proper accident prevention measures. Always use common sense and good judgment. NOTICE SECTION 1: SAFETY Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury. It may also be used to alert against unsafe practices. This symbol is used to alert the user to useful information about proper operation of the machine. Safety Instructions for Machinery OWNER S MANUAL. Read and understand this owner s manual BEFORE using machine. TRAINED OPERATORS ONLY. Untrained operators have a higher risk of being hurt or killed. Only allow trained/supervised people to use this machine. When machine is not being used, disconnect power, remove switch keys, or lock-out machine to prevent unauthorized use especially around children. Make workshop kid proof! DANGEROUS ENVIRONMENTS. Do not use machinery in areas that are wet, cluttered, or have poor lighting. Operating machinery in these areas greatly increases the risk of accidents and injury. MENTAL ALERTNESS REQUIRED. Full mental alertness is required for safe operation of machinery. Never operate under the influence of drugs or alcohol, when tired, or when distracted. ELECTRICAL EQUIPMENT INJURY RISKS. You can be shocked, burned, or killed by touching live electrical components or improperly grounded machinery. To reduce this risk, only allow qualified service personnel to do electrical installation or repair work, and always disconnect power before accessing or exposing electrical equipment. DISCONNECT POWER FIRST. Always disconnect machine from power supply BEFORE making adjustments, changing tooling, or servicing machine. This prevents an injury risk from unintended startup or contact with live electrical components. EYE PROTECTION. Always wear ANSI-approved safety glasses or a face shield when operating or observing machinery to reduce the risk of eye injury or blindness from flying particles. Everyday eyeglasses are not approved safety glasses. -8- Model G0704 (Mfd. Since 04/13)

25 WEARING PROPER APPAREL. Do not wearclothing, apparel or jewelry that can becomeentangled in moving parts. Always tie back orcover long hair. Wear non-slip footwear to avoidaccidental slips, which could cause loss of workpiece control. hazardous dust. Dust created while usingmachinery may cause cancer, birth defects, orlong-term respiratory damage. Be aware of dust hazards associated with each workpiece material, and always wear a NIOSH-approved respirator toreduce your risk. hearing PROTECTION. Always wear hearing protection when operating or observing loudmachinery. Extended exposure to this noisewithout hearing protection can cause permanenthearing loss. REMOVE AdJusTING TOOLs. Tools left onmachinery can become dangerous projectiles upon startup. Never leave chuck keys, wrenches, or any other tools on machine. Always verifyremoval before starting! INTENdEd usage. Only use machine for itsintended purpose and never make modificationsnot approved by Grizzly. Modifying machine orusing it differently than intended may result inmalfunction or mechanical failure that can lead toserious personal injury or death! AWKWARd POsITIONs. Keep proper footing and balance at all times when operating machine. Do not overreach! Avoid awkward hand positionsthat make workpiece control difficult or increasethe risk of accidental injury. ChILdREN & BYsTANdERs. Keep children andbystanders at a safe distance from the work area. Stop using machine if they become a distraction. GuARds & COVERs. Guards and covers reduceaccidental contact with moving parts or flyingdebris. Make sure they are properly installed, undamaged, and working correctly. FORCING MAChINERY. Do not force machine. It will do the job safer and better at the rate forwhich it was designed. NEVER stand ON MAChINE. Serious injurymay occur if machine is tipped or if the cutting tool is unintentionally contacted. stable MAChINE. Unexpected movement during operation greatly increases risk of injury orloss of control. Before starting, verify machine isstable and mobile base (if used) is locked. use RECOMMENdEd ACCEssORIEs. Consultthis owner s manual or the manufacturer for recommended accessories. Using improper accessories will increase the risk of serious injury. unattended OPERATION. To reduce therisk of accidental injury, turn machine off andensure all moving parts completely stop beforewalking away. Never leave machine running while unattended. MAINTAIN WITh CARE. Follow all maintenanceinstructions and lubrication schedules to keepmachine in good working condition. A machinethat is improperly maintained could malfunction, leading to serious personal injury or death. ChECK damaged PARTs. Regularly inspectmachine for any condition that may affect safeoperation. Immediately repair or replace damagedor mis-adjusted parts before operating machine. MAINTAIN POWER CORds. When disconnecting cord-connected machines from power, graband pull the plug NOT the cord. Pulling the cordmay damage the wires inside. Do not handlecord/plug with wet hands. Avoid cord damage bykeeping it away from heated surfaces, high trafficareas, harsh chemicals, and wet/damp locations. EXPERIENCING difficulties. If at any timeyou experience difficulties performing the intended operation, stop using the machine! Contact our Technical Support at (570) Model G0704 (Mfd. Since 04/13) -9-

26 Additional Safety for Mill/Drills UNDERSTANDING CONTROLS. Make sure you understand the use and operation of all controls. SAFETY ACCESSORIES. Always use a chip guard in addition to your safety glasses when milling/drilling to prevent bodily injury. WORK HOLDING. Before starting the machine, be certain the workpiece has been properly clamped to the table. NEVER hold the workpiece by hand when using the mill/drill. CHUCK KEY SAFETY. Always remove your chuck key, drawbar wrench, and any service tools immediately after use. SPINDLE SPEEDS. Select the spindle speed that is appropriate for the type of work and material. Allow the mill/drill to gain full speed before beginning a cut. POWER DISRUPTION. In the event of a local power outage during use of the mill, drill turn OFF all switches to avoid possible sudden start up once power is restored. SPINDLE DIRECTION CHANGES. Never reverse spindle direction while the spindle is turning. MACHINE CARE AND MAINTENANCE. Never operate the mill/drill with damaged or worn parts. Maintain your mill/drill in proper working condition. Perform routine inspections and maintenance promptly. Put away adjustment tools after use. STOPPING SPINDLE. DO NOT stop the mill/drill using your hand against the chuck. BE ATTENTIVE. DO NOT leave the mill/drill running unattended for any reason. DISCONNECT POWER. Make sure the mill/drill is turned OFF, disconnected from its power source and all moving parts have come to a complete stop before starting any inspection, adjustment, or maintenance procedure. AVOIDING ENTANGLEMENT. Keep loose clothing articles such as sleeves, belts or jewelry items away from the spindle. Never wear gloves when operating the mill/drill. TOOL HOLDING. Always use the proper tools for the material you are machining. Make sure they are held firmly in the proper tool holder for the job. CLEAN-UP. DO NOT clear chips by hand. Use a brush, and never clear chips while the spindle is turning. CUTTING TOOL INSPECTION. Inspect drills and end mills for sharpness, chips, or cracks before each use. Replace dull, chipped, or cracked cutting tools immediately. Handle new cutting tools with care. Leading edges are very sharp and can cause lacerations. EXPERIENCING DIFFICULTIES. If at any time you are experiencing difficulties performing the intended operation, stop using the machine! Contact our Technical Support at (570) No list of safety guidelines can be complete. Every shop environment is different. Like all machines there is danger associated with the Model G0704. Accidents are frequently caused by lack of familiarity or failure to pay attention. Use this machine with respect and caution to lessen the possibility of operator injury. If normal safety precautions are overlooked or ignored, serious personal injury may occur Model G0704 (Mfd. Since 04/13)

27 SECTION 2: POWER SUPPLY Availability Before installing the machine, consider the availability and proximity of the required power supply circuit. If an existing circuit does not meet the requirements for this machine, a new circuit must be installed. To minimize the risk of electrocution, fire, or equipment damage, installation work and electrical wiring must be done by an electrican or qualified service personnel in accordance with all applicable codes and standards. Electrocution, fire, or equipment damage may occur if machine is not correctly grounded and connected to the power supply. Circuit Requirements This machine is prewired to operate on a 110V power supply circuit that has a verified ground and meets the following requirements: Nominal Voltage...110V/120V Cycle...60 Hz Phase... Single-Phase Power Supply Circuit Amps A power supply circuit includes all electrical equipment between the breaker box or fuse panel in the building and the machine. The power supply circuit used for this machine must be sized to safely handle the full-load current drawn from the machine for an extended period of time. (If this machine is connected to a circuit protected by fuses, use a time delay fuse marked D.) Full-Load Current Rating The full-load current rating is the amperage a machine draws at 100% of the rated output power. On machines with multiple motors, this is the amperage drawn by the largest motor or sum of all motors and electrical devices that might operate at one time during normal operations. Full-Load Current Rating at 110V Amps The full-load current is not the maximum amount of amps that the machine will draw. If the machine is overloaded, it will draw additional amps beyond the full-load rating. For your own safety and protection of property, consult an electrician if you are unsure about wiring practices or electrical codes in your area. Note: The circuit requirements listed in this manual apply to a dedicated circuit where only one machine will be running at a time. If this machine will be connected to a shared circuit where multiple machines will be running at the same time, consult a qualified electrician to ensure that the circuit is properly sized for safe operation. If the machine is overloaded for a sufficient length of time, damage, overheating, or fire may result especially if connected to an undersized circuit. To reduce the risk of these hazards, avoid overloading the machine during operation and make sure it is connected to a power supply circuit that meets the requirements in the following section. Model G0704 (Mfd. Since 04/13) -11-

28 Grounding & Plug Requirements This machine MUST be grounded. In the event of certain malfunctions or breakdowns, grounding reduces the risk of electric shock by providing a path of least resistance for electric current. This machine is equipped with a power cord that has an equipment-grounding wire and a grounding plug (similar to the figure below). The plug must only be inserted into a matching receptacle (outlet) that is properly installed and grounded in accordance with all local codes and ordinances. Serious injury could occur if you connect the machine to power before completing the setup process. DO NOT connect to power until instructed later in this manual PLUG GROUNDED 5-15 RECEPTACLE Grounding Prong Neutral Hot Figure 3. Typical 5-15 plug and receptacle. Improper connection of the equipment-grounding wire can result in a risk of electric shock. The wire with green insulation (with or without yellow stripes) is the equipment-grounding wire. If repair or replacement of the power cord or plug is necessary, do not connect the equipment-grounding wire to a live (current carrying) terminal. Check with a qualified electrician or service personnel if you do not understand these grounding requirements, or if you are in doubt about whether the tool is properly grounded. If you ever notice that a cord or plug is damaged or worn, disconnect it from power, and immediately replace it with a new one. Extension Cords We do not recommend using an extension cord with this machine. If you must use an extension cord, only use it if absolutely necessary and only on a temporary basis. Extension cords cause voltage drop, which may damage electrical components and shorten motor life. Voltage drop increases as the extension cord size gets longer and the gauge size gets smaller (higher gauge numbers indicate smaller sizes). Any extension cord used with this machine must contain a ground wire, match the required plug and receptacle, and meet the following requirements: Minimum Gauge Size...16 AWG Maximum Length (Shorter is Better)...50 ft. SHOCK HAZARD! Two-prong outlets do not meet the grounding requirements for this machine. Do not modify or use an adapter on the plug provided if it will not fit the outlet, have a qualified electrician install the proper outlet with a verified ground Model G0704 (Mfd. Since 04/13)

29 SECTION 3: SETUP This machine presents serious injury hazards to untrained users. Read through this entire manual to become familiar with the controls and operations before starting the machine! Wear safety glasses during the entire set up process! The Model G0704 is a heavy machine. Serious personal injury may occur if safe moving methods are not used. To be safe, get assistance and use power equipment to move the shipping crate and remove the machine from the crate. Needed for Setup The following are needed to complete the setup process, but are not included with your machine: Description Qty Precision Level... 1 Safety Glasses (for each person)... 1 Standard Screwdriver # Solvent/Cleaner... 1 Shop Rags... 1 Metal Shim Stock... 1 Brass Hammer... 1 Lifting Strap (Rated for at least 500 lbs.)... 1 Lifting Equipment (Rated for at least 500 lbs.)... 1 An Assistant... 1 Unpacking Your machine was carefully packaged for safe transportation. Remove the packaging materials from around your machine and inspect it. If you discover any damage, please call us immediately at (570) for advice. Save the containers and all packing materials for possible inspection by the carrier or its agent. Otherwise, filing a freight claim can be difficult. When you are completely satisfied with the condition of your shipment, inventory the contents. SUFFOCATION HAZARD! Keep children and pets away from plastic bags or packing materials shipped with this machine. Discard immediately. Model G0704 (Mfd. Since 04/13) -13-

30 Inventory The following is a list of items shipped with your machine. Before beginning setup, lay these items out and inventory them. A If any non-proprietary parts are missing (e.g. a nut or a washer), we will gladly replace them; or for the sake of expediency, replacements can be obtained at your local hardware store. Contents Qty A. Mill/Drill w/stand... 1 B. Open End Combo Wrench 17/ C. Open End Combo Wrench 8/ D. Bottle for Oil... 1 E. Tool Box... 1 F. Large Handwheel Handle... 1 G. Small Handwheel Handles... 3 H. T-Bolts M x 60 (vise mounting)... 2 Flat Washers 10mm (vise mounting)... 2 Hex Nuts M (vise mounting)... 2 I. Drill Chuck... 1 J. Chuck Key... 1 K. Phillips Screwdriver... 1 L. Flat Screwdriver... 1 M. Arbor B16 x R N. Hex Wrench Set 2, 3, 4, 5, & 6mm... 1 ea. O. Spindle Pin... 1 Figure 4. G0704 out of the crate. NOTICE If you cannot find an item on this list, carefully check around/inside the machine and packaging materials. Often, these items get lost in packaging materials while unpacking or they are pre-installed at the factory. B C D E Not Shown: Hex Bolts M x Flat Washers 10mm... 4 K L M N O J I H G Figure 5. Inventory. F -14- Model G0704 (Mfd. Since 04/13)

31 Cleanup The unpainted surfaces of your machine are coated with a heavy-duty rust preventative that prevents corrosion during shipment and storage. This rust preventative works extremely well, but it will take a little time to clean. Be patient and do a thorough job cleaning your machine. The time you spend doing this now will give you a better appreciation for the proper care of your machine's unpainted surfaces. There are many ways to remove this rust preventative, but the following steps work well in a wide variety of situations. Always follow the manufacturer s instructions with any cleaning product you use and make sure you work in a well-ventilated area to minimize exposure to toxic fumes. Before cleaning, gather the following: Disposable Rags Cleaner/degreaser (WD 40 works well) Safety glasses & disposable gloves Plastic paint scraper (optional) Gasoline or products with low flash points can explode or cause fire if used to clean machinery. Avoid cleaning with these products. Many cleaning solvents are toxic if concentrated amounts are inhaled. Only work in a well-ventilated area. NOTICE Avoid chlorine-based solvents, such as acetone or brake parts cleaner, that may damage painted surfaces. Test all cleaners in an inconspicuous area before using to make sure they will not damage paint. Basic steps for removing rust preventative: 1. Put on safety glasses. 2. Coat the rust preventative with a liberal amount of cleaner/degreaser, then let it soak for 5 10 minutes. 3. Wipe off the surfaces. If your cleaner/degreaser is effective, the rust preventative will wipe off easily. If you have a plastic paint scraper, scrape off as much as you can first, then wipe off the rest with the rag. 4. Repeat Steps 2 3 as necessary until clean, then coat all unpainted surfaces with a quality metal protectant to prevent rust. Model G0704 (Mfd. Since 04/13) -15-

32 Site Considerations Weight Load Refer to the Machine Data Sheet for the weight of your machine. Make sure that the surface upon which the machine is placed will bear the weight of the machine, additional equipment that may be installed on the machine, and the heaviest workpiece that will be used. Additionally, consider the weight of the operator and any dynamic loading that may occur when operating the machine. Space Allocation Consider the largest size of workpiece that will be processed through this machine and provide enough space around the machine for adequate operator material handling or the installation of auxiliary equipment. With permanent installations, leave enough space around the machine to open or remove doors/covers as required by the maintenance and service described in this manual. See below for required space allocation. Children or untrained people may be seriously injured by this machine. Only install in an access restricted location. Physical Environment The physical environment where the machine is operated is important for safe operation and longevity of machine components. For best results, operate this machine in a dry environment that is free from excessive moisture, hazardous chemicals, airborne abrasives, or extreme conditions. Extreme conditions for this type of machinery are generally those where the ambient temperature range exceeds F; the relative humidity range exceeds 20 95% (non-condensing); or the environment is subject to vibration, shocks, or bumps. Electrical Installation Place this machine near an existing power source. Make sure all power cords are protected from traffic, material handling, moisture, chemicals, or other hazards. Make sure to leave access to a means of disconnecting the power source or engaging a lockout/tagout device, if required. Lighting Lighting around the machine must be adequate enough that operations can be performed safely. Shadows, glare, or strobe effects that may distract or impede the operator must be eliminated. Wall 30" 24" 25" 37.25" 57" Figure 6. Space required for full machine range of motion Model G0704 (Mfd. Since 04/13)

33 Moving & Placing Machine The Model G0704 is a heavy machine. Serious personal injury may occur if safe moving methods are not used. To be safe, get assistance and use power equipment to move the shipping crate and remove the machine from the crate. To remove your machine from the shipping crate and place it in position: 1. Place the crate adjacent to the location where your machine will be placed, then remove the shipping crate from the pallet. 2. Position the stand into the desired location. 5. Unbolt the machine from the pallet, then with an assistant steadying the machine to prevent it from swinging, lift it slightly off of the pallet. Use the cross handwheel to move the table forward or backward as necessary to balance the machine so it hangs as close to level as possible. 6. Lift the machine and carefully place it onto the stand. 7. Bolt the machine to the stand with the four M x 50 hex bolts and flat washers. If you are placing the machine on a workbench, it must be securely mounted to the workbench surface. The strongest mounting option is a "Through Mount" where holes are drilled all the way through the workbench, and hex bolts, washers, and hex nuts are used to secure the machine to the workbench. Hex Bolt 3. Use the vertical handwheel to raise the headstock as far as possible. Machine Base Flat Washer 4. Hang a lifting strap from the fork of a forklift and place it under the head of the mill/drill, as shown in Figure 7. Take care not to place the straps over any controls that may be damaged during transit. Lifting Strap Workbench Flat Washer Lock Washer Hex Nut Figure 8. Example of a through mount setup. Another option for mounting is a "Direct Mount" where the machine is simply secured to the workbench with a lag screw. Lag Screw Flat Washer Machine Base Figure 7. Lifting strap. Model G0704 (Mfd. Since 04/13) Workbench Figure 9. Example of a direct mount setup. -17-

34 Mounting to Shop Floor Although not required, we recommend that you mount your new machine cabinet to the floor. Because this is an optional step and floor materials may vary, floor mounting hardware is not included. Generally, you can either bolt the cabinet to the floor or mount it on machine mounts. Both options are described below. Whichever option you choose, it is necessary to level the cabinet with a precision level. Bolting to Concrete Floors Lag shield anchors with lag bolts and anchor studs (Figure 10) are two popular methods for anchoring an object to a concrete floor. We suggest you research the many options and methods for mounting your machine and choose the best that fits your specific application. Using Machine Mounts Using machine mounts, shown in Figure 11, gives the advantage of fast leveling and vibration reduction. The large size of the foot pads distributes the weight of the machine to reduce strain on the floor. Figure 11. Machine mount example. NOTICE We strongly recommend securing your machine to the floor if it is hardwired to the power source. Consult with your electrician to ensure compliance with local codes. Figure 10. Typical fasteners for mounting to concrete floors. NOTICE Anchor studs are stronger and more permanent alternatives to lag shield anchors; however, they will stick out of the floor, which may cause a tripping hazard if you decide to move your machine Model G0704 (Mfd. Since 04/13)

35 Assembly Drill Chuck Arbor Assembly of the Model G0704 consists of attaching the four handwheel handles to the machine. To assemble your machine: 1. With a #3 standard screwdriver, install the large handwheel handle on the elevation handwheel (Figure 12). Elevation Handwheel Your machine includes an B-16 drill chuck arbor and drill chuck. Before use, the drill chuck must be installed onto the arbor. The This drill chuck installation is intended to be semi-permanent. Tip: For a permanent installation, chill the arbor in the freezer for 15 minutes before performing the following procedure. The taper will expand as it returns to room temperature, permanently locking the chuck. To install the drill chuck onto the arbor: 1. Clean the grease off the drill chuck and all taper mating surfaces. Pay particular attention to the B-16 bore in the drill chuck it must be free from all grease, oil, and debris. Elevation Handwheel Handle Figure 12. Elevation handwheel handle. 2. Use the same method to install the three small handwheel handles to the three table travel handwheels (Figure 13). 2. Retract the drill chuck jaws fully by turning the body of the drill chuck counterclockwise. 3. Insert the arbor into the drill chuck. Tap the arbor lightly with a brass or other soft-headed hammer to get a good fit. Note: While it may not seem like there is anything keeping the drill chuck in place, the B-16 Taper fit provides a strong bond and will hold the drill chuck tightly (Figure 14). R-8 Arbor w/ B-16 Chuck Taper Brass Tip Figure 13. Table handwheel handles. Figure 14. Drill chuck. 4. Refer to Page 29 for detailed instructions for installing or removing the drill chuck and arbor in the spindle. Model G0704 (Mfd. Since 04/13) -19-

36 Test Run Once assembly is complete, test run the machine to ensure it is properly connected to power and safety components are functioning properly. If you find an unusual problem during the test run, immediately stop the machine, disconnect it from power, and fix the problem BEFORE operating the machine again. The Troubleshooting table in the SERVICE section of this manual can help. The test run consists of verifying the following: 1) The motor powers up and runs correctly, and 2) the Emergency Stop button stops spindle rotation. Serious injury or death can result from using this machine BEFORE understanding its controls and related safety information. DO NOT operate, or allow others to operate, machine until the information is understood. DO NOT start machine until all preceding setup instructions have been performed. Operating an improperly set up machine may result in malfunction or unexpected results that can lead to serious injury, death, or machine/property damage. To test run machine: 1. Clear all setup tools away from the machine. 2. Make sure the machine is properly lubricated (see Page 36). 3. Make sure there are no obstructions around or underneath the spindle. 4. Place the spindle direction selection knob in the "0" (OFF) position and press the Emergency Stop button (see Figure 15). Spindle RPM Readout Emergency Stop Button Figure 15. Test run controls. Spindle Direction Knob Variable Spindle Speed Knob 5. Connect the mill/drill to the power source. 6. Turn the speed range selector knob to the "L" (low) position (see Figure 1 on Page 3) and rotate the variable spindle speed knob all the way to the left (slowest) position. 7. Place the spindle direction knob in the "F" (Forward) position. Squeeze the tab on the Emergency Stop button, pull it open, then press the green button. The spindle will begin to turn at a low RPM. When operating correctly, the machine runs smoothly with little or no vibration or rubbing noises. Investigate and correct strange or unusual noises or vibrations before operating the machine further. Always disconnect the machine from power when investigating or correcting potential problems. 8. Press the Emergency Stop button. The machine should stop. If the machine does stop, the Emergency Stop button safety feature is working correctly. Continue to Step 8. If the machine does not stop, the Emergency Stop button safety feature is not working correctly. This safety feature must work properly before proceeding with regular operations. Call Tech Support for help. Congratulations! The test run is complete. Perform the following Spindle Break-In procedure Model G0704 (Mfd. Since 04/13)

37 Spindle Break-In The spindle break-in procedure distributes lubrication throughout the bearings to reduce the risk of early bearing failure if there are any "dry" spots or areas where lubrication has settled in the bearings. You must complete this procedure before placing operational loads on the spindle for the first time when the machine is new or if it has been sitting idle for longer than 6 months. Always start the spindle break-in at the lowest speed to minimize wear if there are dry spots. Allow the spindle to run long enough to warm up and distribute the bearing grease, then incrementally increase spindle speeds and repeat this process at each speed until reaching the maximum spindle speed. Following the break-in procedure in this progressive manner helps minimize any potential wear that could occur before lubrication is fully distributed. To perform spindle break-in process: 1. Successfully complete Test Run procedure beginning on Page Open the Emergency Stop button cover and press the green button to start the spindle. 3. With the speed range selector knob in the "L" (low) position, turn mill/drill ON and run the spindle at 600 RPM for a minimum of 10 minutes in each direction of rotation. 4. Turn the mill/drill OFF. 5. With the speed range selector knob in the "H" (high) position, turn mill/drill ON and run spindle at 1000 RPM for 5 minutes in each direction of rotation. 6. Repeat Step 5 at 2000 RPM. 7. Turn the mill/drill OFF. Congratulations! The spindle break-in is complete. Complete the spindle bearing break-in procedure to prevent rapid wear and tear of spindle components once the machine is placed into operation. DO NOT perform this procedure independently of the Test Run section. The machine could be seriously damaged if the controls are set differently than instructed in that section. Model G0704 (Mfd. Since 04/13) -21-

38 SECTION 4: OPERATIONS Operation Overview The purpose of this overview is to provide the novice machine operator with a basic understanding of how the machine is used during operation, so the machine controls/components discussed later in this manual are easier to understand. Due to the generic nature of this overview, it is not intended to be an instructional guide. To learn more about specific operations, read this entire manual and seek additional training from experienced machine operators, and do additional research outside of this manual by reading "howto" books, trade magazines, or websites. To reduce the risk of serious injury when using this machine, read and understand this entire manual before operating. To complete a typical operation, the operator does the following: 1. Loosens the vertical travel locks, then adjusts the headstock height above the table to ensure there is sufficient room to install the tooling in the spindle and the workpiece on the table. 2. Installs the desired tooling for the job. 3. Positions the workpiece as needed for the operation, then clamps the workpiece using applicable clamping devices, or a vise that is already mounted on the table to ensure the workpiece does not move during the milling/ drilling operation. 4. Positions the cutter or drill bit near the workpiece, then tightens vertical travel locks. 5. Selects the appropriate spindle speed for the milling or drilling operation using the speed selector knob and variable spindle speed knob. 6. Unlocks the X- and Y-axis table locks. Damage to your eyes and lungs could result from using this machine without proper protective gear. Always wear safety glasses and a respirator when operating this machine. NOTICE If you have never used this type of machine or equipment before, WE STRONGLY REC- OMMEND that you read books, review industry trade magazines, or get formal training before beginning any projects. Regardless of the content in this section, Grizzly Industrial will not be held liable for accidents caused by lack of training. 7. Wears safety glasses or a face shield. 8. Turns the spindle direction selection knob to the desired direction. 9. Loosens the quill lock lever and uses the quill feed lever or the fine feed knob to set the cutting tool height according to the workpiece. 10. For milling operations, uses the table handwheels to move the table so the cutter removes material evenly from the workpiece. For drilling operations, uses the quill feed lever or fine feed knob to lower the drill bit into the workpiece, then raises the drill bit out of the workpiece using the same controls. 11. Turns the spindle direction knob to the "0" position to stop the spindle Model G0704 (Mfd. Since 04/13)

39 Basic Controls To reduce the risk of serious injury when using this machine, read and understand this entire manual before beginning any operations. Speed Range Selector Knob Fine Feed Knob Vertical Handwheel Vertical Travel Locks Loose hair, clothing, or jewelry could get caught in machinery and cause serious personal injury. Keep these items away from moving parts at all times to reduce this risk. Use the descriptions and figures below to become familiar with the basic controls of your machine. Vertical Handwheel: Raises and lowers the headstock (Z-Axis). Speed Range Selector Knob: Selects low range (L) or high range (H) for the spindle speed. Vertical Travel Locks: Lock the position of the headstock to the column. Fine Feed Lock Knob: Engages the fine feed knob for precise control of vertical quill travel. Fine Feed Knob: Provides fine control over vertical quill travel. Quill Feed Levers: Provide coarse control over vertical quill travel. Fine Feed Lock Knob Figure 16. Head controls. Quill Feed Lever Drawbar Cap: Covers the drawbar and upper portion of the spindle. Drawbar: Secures collets and tooling in the spindle taper. Spindle and Chuck: Provide a mounting place for tooling. Quill Lock Lever: Locks the vertical position of the quill when tightened. Quill Lock Lever Drawbar Cap & Drawbar Spindle & Chuck Figure 17. Headstock controls (continued). Model G0704 (Mfd. Since 04/13) -23-

40 Cross Handwheel: Moves the table forward and backward (Y-Axis). Longitudinal Handwheels: Move the table from side to side (X-Axis). Longitudinal Table Locks: Lock the longitudinal position of the table when tightened. Cross Table Locks: Lock the cross position of the table when tightened. Power Button: Turns display ON/OFF. ZERO Button: Resets the display to 0.000". Hold down until "S" flashes on the readout to enable or buttons. IN/MM Button: Toggles the units displayed. Button: Increases the current depth reading. Button: Decreases the current depth reading. Longitudinal Table Locks Longitudinal Handwheels IN/MM Button Power Button ZERO Button Button Cross Handwheel Cross Table Locks Figure 18. Table controls. Spindle RPM Readout: Displays the speed of the spindle rotation. Button Figure 20. Digital readout unit controls. Emergency Stop Button: Interrupts the flow of power to the machine. Variable Spindle Speed Knob: Changes the speed of the spindle rotation. Spindle Direction Selection Knob: Changes the direction of spindle rotation. Spindle RPM Readout Emergency Stop Button Variable Spindle Speed Knob Spindle Direction Selection Knob Figure 19. Control panel Model G0704 (Mfd. Since 04/13)

41 Digital Readout Unit The digital readout unit gives a precise reading of the vertical positioning of the quill. It can be zeroed at any position and manually increased or decreased independent of quill position when the operation requires it (see Figure 21). IN/MM Button Button Button Power Button ZERO Button Battery Cover Figure 21. Digital readout controls. To use the digital readout: 1. Press the power button (see Figure 21). A reading should appear on the display. 2. Press the IN/MM button to select whether units will be displayed in inches or millimeters. Each press of the button switches from one unit to the other. 3. If you want to "zero" the readout at any time, press the ZERO button. The current reading will be cleared and the scale will be reset to If you want to increase or decrease the reading at any time, press the ZERO button and hold it until "S" flashes on the display. Press the appropriate or button, then press the ZERO button again. This is useful when calibrating the mill to known dimensions on a workpiece. 4. Press the ZERO button and hold until "S" flashes, press the or button until the display reads 0.000, then press the ZERO button. 5. When the operation is complete, press the power button to conserve the battery. Model G0704 (Mfd. Since 04/13) -25-

42 Calculating Spindle Speed Closely follow the proper spindle speed and proper feed rate to produce good results, reduce undue strain on all moving parts and increase operator safety. Prior to milling, determine the spindle speed needed to cut your workpiece, then set the speed on the machine. To determine the needed spindle speed: 1. Use the table in Figure 22 to determine the cutting speed required for the material of your workpiece. 2. Measure the diameter of your cutting tool in inches. 3. Use the following formula to determine the needed spindle RPM for your operation: Cutting Speeds for High Speed Steel (HSS) Cutting Tools Workpiece Material Cutting Speed (sfm) Aluminum & Alloys 300 Brass & Bronze 150 Copper 100 Cast Iron, soft 80 Cast Iron, hard 50 Mild Steel 90 Cast Steel 80 Alloy Steel, hard 40 Tool Steel 50 Stainless Steel 60 Titanium 50 Plastics Wood Note: For carbide cutting tools, double the cutting speed. These values are a guideline only. Refer to the MACHINERY'S HANDBOOK for more detailed information. Figure 22. Cutting speed table for HSS cutting tools. (Cutting Speed x 4) /Tool Diameter = RPM -26- Model G0704 (Mfd. Since 04/13)

43 Spindle Speed and Direction Setting the speed on the Model G0704 is a two part process. The gearbox in the headstock has two gear ranges and the motor is a variable speed unit. Together, these two systems provide an overall speed range of RPM. When the dial is turned up all the way, the motor draws the full amperage level. When combined with a cutting load, the motor can overheat and become damaged. If high speeds are needed, put the speed range into high "H" then turn the variable speed dial down, away from the maximum position. If the maximum RPM is needed, reduce the cutting load as much as possible and minimize the operation time at these speeds. Note: It may be necessary to rotate the spindle by hand to get the gears to mesh properly. 3. Make sure the work area is clear and that all safety precautions are taken. 4. Turn the variable spindle speed knob to the far left (slowest) position, then press the green start button and use the spindle direction selection knob to choose the direction of spindle travel and start spindle rotation (Figure 24). RPM Readout To set the spindle speed: 1. Determine the appropriate spindle speed for your operation. See Calculating Spindle Speed on Page Select the appropriate speed range using the speed range selector knob (see Figure 23). "H" represents the high speed range, which is capable of spindle speeds from RPM. "L" represents the low range, which is capable of spindle speeds from RPM. Note: To maximize spindle torque, use the low range. Speed Selection Knob Variable Spindle Speed Knob Figure 24. Spindle direction selection knob. 5. Watch the RPM readout and adjust the variable spindle speed knob as needed until the desired RPM is reached. NOTICE Spindle Direction Selection Knob AVOID OVERHEATING MOTOR! DO NOT operate with variable speed dial at full RPM for than a couple minutes or motor overheating may occur. Instead, achieve the same spindle speed by using the high H speed range and reducing the motor RPM by turning the variable speed dial down. Figure 23. Speed selector knob. Model G0704 (Mfd. Since 04/13) -27-

44 Spindle Height Controls The spindle height is controlled by the quill feed lever and the fine feed knob. Fine Feed Knob Quill Feed Lever Changing Spindle Position Using Fine Feed Knob 1. Unlock the quill lock lever and tighten the fine feed lock knob. 2. Rotate the fine feed knob to lower or raise the spindle in small increments. Observe the scale on the knob or the digital readout to monitor movement in thousandths of an inch (Figure 26). Spindle Height Scale Fine Feed Scale Fine Feed Lock Knob Quill Feed Lever Quill lock lever Figure 25. Spindle controls. Fine Feed Lock Knob Changing Spindle Position Using Quill Feed Levers 1. Unlock the quill lock lever and loosen the fine feed lock knob. 2. Pull down on any of the coarse downfeed levers to adjust the vertical position of the spindle. Observe the spindle height scale or digital readout to monitor movement in inches or millimeters. Tip: Milling with the spindle fully extended can cause tool chatter. For maximum spindle rigidity when milling, it is better to keep the spindle retracted into the headstock as far as possible with the spindle lock and the downfeed selector knob tightened. Quill lock lever Fine Feed Knob Figure 26. Fine spindle feed controls. 3. Tighten the quill lock lever to hold the spindle in a particular position if you choose. Tip: Milling with the spindle fully extended can cause tool chatter. For maximum spindle rigidity when milling, it is better to keep the spindle retracted into the headstock as far as possible with the quill lock lever tightened, and the fine feed knob tightened Model G0704 (Mfd. Since 04/13)

45 Drill Chuck To install the drill chuck and arbor: 1. DISCONNECT MILL/DRILL FROM POWER! 2. Remove the drawbar cap. 3. Insert the chuck arbor into the spindle, making sure to line up the slot in the arbor with the pin in the spindle. 4. Thread the drawbar into the arbor until the arbor is seated up into the spindle taper. 5. Use the included spindle pin to prevent the spindle from turning while you use an 8mm wrench to tighten the drawbar. Drawbar Spindle Pin Figure 27. Tightening the drawbar. Note: Do not overtighten the drawbar. Overtightening makes arbor removal difficult and will damage the arbor and threads. NOTICE The Model G0704 drawbar will extract the arbor from the spindle. Once the arbor or collet has broken free from the spindle taper, be sure to properly support it while continuing to loosen the drawbar. Failure to properly support the arbor or collet while loosening the drawbar will result in the arbor or collet falling out of the spindle, causing damage to machine components. To remove the chuck and arbor from the spindle: 1. DISCONNECT MILL/DRILL FROM POWER! 2. Remove the drawbar cap. 3. Lock the quill in place with the quill lock lever. 4. Use the included spindle pin to prevent the spindle from turning while you use an 8mm wrench to loosen the drawbar 2 3 turns. DO NOT continue loosening the drawbar without supporting the drill chuck or it will fall from the spindle. 5. Hold the chuck with one hand and finish loosening the drawbar until the chuck falls out of the spindle. Note: The chuck is attached to the arbor using a B-16 taper. This attachment is considered to be semi-permanent. There should be no need to remove the chuck from the arbor. 6. Re-install the drawbar cap. Model G0704 (Mfd. Since 04/13) -29-

46 Loading Tooling Your Model G0704 features an R-8 spindle taper, which gives the freedom to use standard R-8 cutting tools and collets. These optional collets come in many sizes, typically ranging from 1 16" to 7 8" and 3mm to 20mm, and should be matched to your cutting tool shank size. To install the tooling: 1. DISCONNECT MILL/DRILL FROM POWER! 2. Remove the drawbar cap. 3. Carefully clean the surface of the tooling and spindle taper. Ensure that it is free of debris and is lightly oiled. 4. If you are using a cutting tool and collet, insert the cutting tool into the collet, then insert the collet up into the spindle taper, making sure the slot in the collet lines up with the pin in the spindle. If you are using a cutting tool that installs directly into the spindle, insert the tool into the spindle taper, making sure the slot in the tool lines up with the pin in the spindle. 5. Slide the tooling upward until it makes contact with the drawbar threads. 6. Hand thread the drawbar into the tooling until the tooling draws up into the spindle taper. 7. Use the included spindle pin to prevent the spindle from turning while you use an 8mm wrench to tighten the drawbar. Note: Do not overtighten the drawbar. Overtightening makes collet removal difficult and will damage the drawbar threads, collet, and the spindle taper. Keep in mind that the taper keeps the collet and tool in place. The drawbar simply aids in seating the taper. To remove the collet: 1. DISCONNECT MILL/DRILL FROM POWER! 2. Remove the drawbar cap. 3. Lock the quill in place with the quill lock lever. 4. Use the included spindle pin to prevent the spindle from turning while you use an 8mm wrench to loosen the drawbar 2 3 turns. DO NOT continue loosening the drawbar without supporting the collet or it will fall from the spindle. LACERATION HAZARD! Leading edges of end mills and other cutting tools can be very sharp. Protect your hands with gloves or a shop towel when handling. NOTICE The Model G0704 drawbar will extract the arbor from the spindle. Once the arbor or collet has broken free from the spindle taper, be sure to properly support it while continuing to loosen the drawbar. Failure to properly support the arbor or collet while loosening the drawbar will result in the arbor or collet falling out of the spindle, causing damage to machine components. 5. Protect the table surface with a piece of cardboard and hold the cutter/tool with a shop towel to prevent it from falling out of the collet. Continue loosening the drawbar until the collet is freed from the spindle Model G0704 (Mfd. Since 04/13)

47 Headstock Travel (Z-Axis and Rotation) To tilt the headstock to the left or right: 1. DISCONNECT MILL/DRILL FROM POWER. Headstock height is adjustable in the vertical Z-axis to accept large workpieces. For unique milling operations, the headstock can be tilted right or left between 0 and 90. To raise or lower the headstock: 1. Unlock the vertical travel lock levers shown in Figure 28. During the following steps, be aware that the headstock is top-heavy and will swing if it is not well supported once the center bolt and lock nut are loosened. Always support the headstock with one hand when loosening these fasteners. Failure to do so may result in unexpected movement of the headstock, causing damage to the machine and personal injury. Vertical Handwheel 2. Support the headstock with one hand, then using the included 17/19mm combo wrench, loosen the headstock center bolt and three angle lock nuts (Figure 29). Vertical Travel Lock Levers Center Bolt Figure 28. Headstock slide controls. 2. Turn the vertical handwheel shown in Figure 28 to raise or lower the headstock, then lock the vertical travel lock levers. Note: For maximum spindle rigidity when milling, keep the spindle retracted into the headstock as far as possible with the quill lock lever locked and with the fine feed lock knob tightened. Angle Lock Nut 1 of 3 Tilt Scale Figure 29. Headstock tilt controls. 3. While watching the tilt scale, rotate the headstock to the required angle, then retighten the center bolt and angle lock nut to hold the headstock in place. Model G0704 (Mfd. Since 04/13) -31-

48 Table Travel X-Axis Handwheels The mill/drill table can be moved in the longitudinal (X-axis) and cross (Y-axis) directions. Longitudinal Feed The X-axis is moved by the handwheels shown in Figure 30 at the end of the table. These handwheels will move the table in both directions side-to-side. One complete revolution of either handwheel moves the longitudinal feed 0.100". There is also a scale on the front of the table for use when a tight tolerance is not required. The longitudinal feed can be locked in position by table locks located on the front of the table (see Figure 31). Cross Feed The Y-axis shown in Figure 30, is moved with the handwheel on the front of the table base. One complete revolution of the handwheel moves the cross slide 0.100". The cross feed can be locked into position by a table lock lever located on the right side of the cross slide underneath the table (see Figure 31). Y-Axis Handwheel Figure 30. Table X- and Y-axis controls. X-Axis Table Lock Levers X-Axis Scale Y-Axis Table Lock Levers Figure 31. Table locks and scales Model G0704 (Mfd. Since 04/13)

49 ACCESSORIES SECTION 5: ACCESSORIES Installing unapproved accessories may cause machine to malfunction, resulting in serious personal injury or machine damage. To reduce this risk, only install accessories recommended for this machine by Grizzly. H8177 Worktable with Angle Enjoy having an economical way to support your workpiece at an array of angles. This high-quality tilting worktable is quick and easy to setup and use. NOTICE Refer to our website or latest catalog for additional recommended accessories. H8179 Horizontal Milling Table Take advantage of the G0704 mill/drill 90 tilting headstock feature. Install this lifted cast-iron horizontal milling table for the correct clearance when making those side-milling operations. Figure 33. Worktable with angle. G5684 R-8 Vertical Collet Rack No more loose R-8 collets laying around in your tool box. Organize with this handy collet rack and you won t be looking at each one for the correct size. Set on your bench or mount to a wall. Holds 48 collets. H8179 Figure 32. Horizontal milling worktable. Figure 34. Model G5684 Tilt Table. order online at or call Model G0704 (Mfd. Since 04/13) -33-

50 G9322 Boring Head Combo Set Hardened and ground adjusting screws along with a wide base design guarantee a long life and trouble-free use. Includes a 2" boring head, R-8 arbor with 7 /16"-20 TPI, and a 12 piece 3 /4" boring bar set. H5685 4" Rotary Table The perfect rotary table for all you model makers and those doing smaller precision work. Comes with clamping kit. Figure 35. G9324 Boring Head Combo Set. G PC. 2 & 4 Flute TiN End Mill Set. Includes these sizes and styles in two and four flute styles: 3 /16", 1 /4", 5 /16", 3 /8", 7 /16", 1 /2", 9 /16", 5 /8", 3 /8", 11 /16", and 3 /4". Figure 38. H5685 4" Rotary Table. Basic Eye Protection T20501 Face Shield Crown Protector 4" T20502 Face Shield Crown Protector 7" T20503 Face Shield Window T20451 Kirova Clear Safety Glasses T20452 Kirova Anti-Reflective S. Glasses H7194 Bifocal Safety Glasses 1.5 H7195 Bifocal Safety Glasses 2.0 H7196 Bifocal Safety Glasses 2.5 T20502 Figure 36. G PC End Mill Set. D2260A Mini Shop Fox Mobile Base Don't let the little size of this one fool you. It shares the same design concepts as its two bigger brothers, giving you an amazing 600 lb. load capacity in one small package! T20503 T20452 H7194 T20451 Figure 39. Assortment of basic eye protection. Figure 37. Model D2260A Mini Shop Fox Mobile Base. order online at or call Model G0704 (Mfd. Since 04/13)

51 G9512 T-Slot Nuts, 4 PK, 1 /2" Slot, 3 /8"-16 Heat treated steel T-Slot Nuts with black oxide finish feature an imperfect thread in the base of the T-nut to eliminate any danger of screwing the clamping stud through and damaging the table slot. G9849 Magnetic Base/Dial Indicator Combo Precision measurements and setups have never been so easy. Magnetic base engages with just the turn of a switch and allows pinpoint adjustment. The dial indicator features 0-1" travel and has a resolution of 0.001". This fine set includes a molded case for protection and convenience. Figure 40. Model G9512 T-Slot Nuts. G5758 Tilt Table 5" x 7" Set your work at any angle with these sturdy tilt tables. Heavy-duty construction includes T-slots, two locking screws and precision base that allows the table to tilt from -45 Degrees to +45 Degrees. Table size: 5" x 7". Figure 42. Model G9849 Indicator/Base Combo SB1365 South Bend Way Oil-ISO 68, 12 oz. T23964 Moly-D Multi-purpose NLGI#2 Grease Figure 41. Model G5758 Tilt Table. Figure 43. Recommended products for machine lubrication. order online at or call Model G0704 (Mfd. Since 04/13) -35-

52 SECTION 6: MAINTENANCE Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious personal injury. Schedule For optimum performance from your machine, follow this maintenance schedule and refer to any specific instructions given in this section. Figure 44. Vertical way lube location (both sides). Daily Check: Make sure mill/drill is disconnected from power when not in use. Check for loose mounting bolts. Make sure mill/drill is clean and lubricated. Check for worn or damaged wires. Check for any other unsafe condition. Monthly Check: Check that gibs are adjusted properly. Biannual Check: Lubricate headstock lead screw and gears. Lubrication Figure 45. Cross way lube locations. Regular lubrication will ensure your mill/drill performs at its highest potential. Regularly wipe all sliding surfaces with SB1365 Way Oil (Page 35) or a light machine oil, then move the components back and forth several times to ensure smooth movements (Figures 44 46). Every six months, or more often with heavy use, clean and lubricate the leadscrews and vertical handwheel ring & pinion gears, as outlined on Page 38. Protect other unpainted cast iron surfaces with regular applications of products like G96 Gun Treatment, SLIPIT, or Boeshield T-9. Figure 46. Longitudinal way lube locations Model G0704 (Mfd. Since 04/13)

53 Every six months, or more frequently under heavy use, we recommend that you clean and lubricate the leadscrews and vertical handwheel gears with a light machine oil and multi-purpose grease. Tools Needed: Qty Hex Wrench 3, 4mm... 1 Multi-Purpose Lithium Grease... 1 Paint Brush for Grease Application... 1 Oil Bottle of 10-30w Synthetic Oil... 1 Stiff-Bristled Nylon Brush for Cleaning... 1 Mineral Spirits... As needed for cleaning Shop Rags... As needed for cleaning 6. Lift or remove the rubber way cover, then use mineral spirits and a brush to clean as much of the existing grease and debris as possible off of the cross travel leadscrew shown in Figure 48. Allow leadscrew to dry. To lubricate the leadscrews: 1. DISCONNECT MILL/DRILL FROM POWER! 2. Lower the headstock as far as you can without the spindle contacting the table surface. 3. Use mineral spirits and a brush to clean as much of the existing grease and debris as possible off of the vertical leadscrew shown in Figure 47. Allow leadscrew to dry. Figure 48. Cross travel leadscrew location. 7. Apply light machine oil to the exposed leadscrew threads, then move the table through its full range of cross motion several times to disperse the oil along the full length of the leadscrew. 8. Using the longitudinal handwheel, move the table as far to one side as possible. 9. From beneath the table, use mineral spirits and a brush to clean as much of the existing grease and debris as possible off of the longitudinal travel leadscrew shown in Figure 49. Allow the leadscrew to dry. Figure 47. Vertical leadscrew location. 4. Apply light machine oil to the exposed leadscrew threads, then move the headstock through its full range of motion several times to disperse the oil along the full length of the leadscrew. 5. Using the cross handwheel, move the table as far forward as possible. Model G0704 (Mfd. Since 04/13) Figure 49. Longitudinal leadscrew location. 10. Apply light machine oil to the exposed leadscrew threads, then move the table through its full range of longitudinal motion several times to disperse the oil along the full length of the leadscrew. -37-

54 To lubricate the vertical leadscrew bushing and ring & pinion gears: 1. DISCONNECT MILL/DRILL FROM POWER! 5. Remove the acorn nut and flat washer that secure the vertical handwheel, then remove the handwheel (Figure 52). 2. Remove the bushing cap by unthreading the four cap screws that secure it (Figure 50). Bushing Cap Figure 52. Handwheel removal. Figure 50. Bushing cap removal. 6. Remove the four cap screws that secure the handwheel shaft pillow block, then carefully remove the assembly (Figure 53). 3. Apply several drops of light machine oil to the bushing edge, then rotate the vertical handwheel to disperse the oil (Figure 51). Pillow Block Ring Gear Pinion Gear Figure 53. Handwheel gears. Figure 51. Bushing oil location. 4. Replace the bushing cap. 7. Use mineral spirits and a brush and rag to clean as much of the existing grease and debris as possible off of the ring and pinion gears. Allow the parts to dry. 8. Apply a liberal coat of multi-purpose grease to the pinion gear. 9. Re-assemble the machine by reversing the steps above Model G0704 (Mfd. Since 04/13)

55 Troubleshooting SECTION 7: SERVICE Review the troubleshooting and procedures in this section if a problem develops with your machine. If you need replacement parts or additional help with a procedure, call our Technical Support at (570) Note: Please gather the serial number and manufacture date of your machine before calling. Troubleshooting Symptom Possible Cause Possible Solution Machine does not 1. Circuit breaker on machine tripped. start. Machine stalls or is overloaded. Machine has vibration or noisy operation. 2. Plug at fault or wired incorrectly. 3. Motor wired incorrectly. 4. Wall fuse/circuit breaker is blown/tripped. 5. Wiring is open/has high resistance. 6. Machine power switch is at fault. 7. Motor is at fault. 1. Feed rate/cutting speed too fast. 2. Wrong cutter type. 3. Machine is undersized for the task or tooling is incorrect for the task. 4. Motor connection is wired incorrectly. 5. Motor bearings are at fault. 6. Motor has overheated. 7. Motor is at fault. 1. Motor or machine component is loose. 2. Excessive depth of cut. 3. Cutter/tooling is loose. 4. Cutter is dull or at fault. 5. Bit is chattering. 6. Machine is incorrectly mounted or sits unevenly. 7. Motor bearings are at fault. 1. Press reset button on motor junction box; reduce load on motor to prevent overheating. 2. Ensure plug is not damaged and is wired correctly. 3. Ensure motor wiring is correct. 4. Ensure circuit size is correct and a short does not exist. Reset breaker or replace fuse. 5. Check for broken wires or disconnected/corroded connections; repair/replace as necessary. 6. Ensure switch is wired correctly; replace if at fault. 7. Test/repair/replace. 1. Decrease feed rate/cutting speed. 2. Use the correct cutter for the task. 3. Use smaller or sharper tooling; reduce feed rate or spindle speed; use cutting fluid if possible. 4. Wire motor correctly for the intended voltage. 5. Test by rotating shaft; rotational grinding/loose shaft requires bearing replacement. 6. Clean off motor, let cool, and reduce workload. 7. Test/repair/replace motor. 1. Inspect/replace stripped or damaged bolts/nuts, and re-tighten with thread locking fluid. 2. Decrease depth of cut. 3. Make sure tooling is properly secured. 4. Replace/resharpen cutter. 5. Replace/sharpen bit; index bit to workpiece; use appropriate feed rate and cutting RPM. 6. Tighten/replace mounting bolts in bench; relocate/ shim machine. 7. Test by rotating shaft; rotational grinding/loose shaft requires bearing replacement. Model G0704 (Mfd. Since 04/13) -39-

56 Symptom Possible Cause Possible Solution Tool slips in collet. Breaking tools or cutters. Workpiece vibrates or chatters during operation. Table is hard to move. Bad surface finish. 1. Collet is not fully drawn up into spindle taper. 2. Wrong size collet. 3. Debris on collet or in spindle taper. 4. Taking too big of a cut. 1. Spindle speed too slow/feed rate is too fast. 2. Cutting tool getting too hot. 3. Taking too big of a cut. 4. Spindle extended too far down. 1. Table locks not tight. 2. Quill lock lever not tight. 3. Workpiece not securely clamped to table or into mill vice. 4. Spindle speed is too slow /feed rate is too fast. 5. Spindle extended too far down. 1. Table locks are tightened down. 2. Chips have loaded up on ways. 3. Ways are dry and need lubrication. 4. Table limit stops are interfering. 5. Gibs are too tight. 1. Spindle speed is too slow/feed rate is too fast. 2. Using a dull or incorrect cutting tool. 3. Wrong rotation of cutting tool. 4. Workpiece not securely clamped. 5. Spindle extended too far down. 1. Tighten drawbar. 2. Measure tool shank diameter and match with appropriate diameter collet. 3. Clean collet and spindle taper. 4. Lessen depth of cut and allow chips to clear. 1. Set spindle speed correctly (Page 27) or use a slower feed rate. 2. Use coolant fluid or oil for appropriate application. (Follow cutting fluid manufacturer's recommendation for proper use and safety.) 3. Decrease depth of cut. 4. Fully retract spindle and lower headstock. This increases rigidity. 1. Tighten down table locks (Page 32). 2. Tighten quill lock lever. 3. Check that clamping is tight and sufficient for the job. Make sure mill vice is tight to the table. 4. Set spindle speed correctly (Page 27) or use a slower feed rate. 5. Fully retract spindle and lower headstock. This increases rigidity. 1. Make sure table locks are fully released. 2. Frequently clean away chips that load up during milling operations. 3. Lubricate ways and handles (Page 36). 4. Check to make sure that all table limit stops are not in the way. 5. Adjust gibs (see Page 41). 1. Set spindle speed correctly (Page 27 or use a slower feed rate. 2. Sharpen cutting tool or select one that better suits the operation. 3. Check for proper cutting rotation for cutting tool. 4. Secure properly to the table. 5. Fully retract spindle and lower headstock. This increases rigidity Model G0704 (Mfd. Since 04/13)

57 Gibs Gibs are wedge-shaped pieces of metal that fill the gap between the sliding surfaces of the machine. By adjusting the position of the gib in its gap, you can remove any play that might exist between the adjacent components. The gibs are pre-adjusted at the factory but due to storage, break-in, and usage, may require adjustment. If movement seems too tight at first, make sure that all the rust preventative that was shipped on the machine is removed from the ways. Lubricate the ways with oil, and work the table back-and-forth several times until the movement is easier. To adjust the headstock gibs: 1. DISCONNECT MILL/DRILL FROM POWER! 2. Remove the two screws that secure the top end of the way cover, pull it down to expose the lower gib screw, then loosen the vertical travel locks (Figure 55). Upper Gib Screw Vertical Travel Locks To adjust the table gibs: 1. DISCONNECT MILL/DRILL FROM POWER! 2. Loosen the table travel locks (Figure 54). Locations of Corresponding Gib Screws Way Cover Lower Gib Screw Figure 55. Headstock gib adjustment. 3. Loosen or tighten the upper and lower gib screws (Figure 55) in an alternating manner to adjust the headstock gib. Cross Gib Screw (1 of 2 shown) Longitudinal Gib Screw (1 of 2 shown) The headstock should slide smoothly with no play or looseness. Do not overtighten the gibs or premature slide and gib wear will occur. 4. Lubricate the headstock way and gib. 5. Re-install the way cover. Figure 54. Table gib adjustment screw locations. 3. Loosen or tighten the front and rear gib screws (Figure 54) in an alternating manner to adjust the cross travel gib. The table should slide smoothly in the cross direction with no play or looseness. Do not overtighten the gibs or premature slide and gib wear will occur. 4. Lubricate the cross way and gib. 5. Repeat the process for the longitudinal way gib using the gib adjustment screws on the left and right sides of the table base. Model G0704 (Mfd. Since 04/13) -41-

58 Leadscrew Backlash When you turn the handwheels to adjust the position of the table, you will notice slight play (backlash) in the handwheel before the table begins to move. If this play is greater than 0.008" (measured with the dial at the base of each handwheel), then you will need to adjust the leadscrew nuts. To reach the adjustment screws on the leadscrew nut, you may have to fabricate extensions for your hex wrenches. When adjusting, make adjustments in small increments. Attempting to reduce backlash to less than 0.003" is impractical and will add unnecessary wear to both the leadscrews and the leadscrew nuts. To adjust the X-axis leadscrew: 1. Locate the X-axis leadscrew nut under the middle of the table. The head on the adjustment screws face to the right (Figure 56). To adjust the Y-axis leadscrew nut: 1. Locate the leadscrew nut underneath the table through the hole in the base under the rubber way cover. 2. Tighten the adjustment screws on the leadscrew nut in the same manner as described for the X-axis leadscrew adjustment. 3. Test the adjustment by turning one of the cross handwheels. The ideal amount of play when properly adjusted is 0.003" 0.006". Digital Readout Unit Battery Replacement If the digital readout unit stops functioning, the battery must be replaced. To replace the digital readout unit battery: Location of Adjustment Screws 1. Use a wide (#3) standard screwdriver or the edge of a coin to remove the battery cover (Figure 57). Figure 56. X-axis leadscrew adjusters. 2. Tighten the adjustment screws. 3. Test the adjustment by turning one of the longitudinal handwheels. The ideal amount of play when properly adjusted is 0.003" 0.006". Battery Cover Figure 57. Battery replacement. 2. Remove the old battery, dispose of it according to state and federal regulations, then replace it with a new one. 3. Replace the battery cover Model G0704 (Mfd. Since 04/13)

59 Motor Service 3. Unscrew one of the brush caps to expose the brush assembly (Figure 59). The bearings inside the motor are shielded and lubricated for the life of the bearing and require no routine maintenance. This motor is equipped with long life carbon brushes. Brush life expectancy is affected by motor loading. Heavy motor loading will result in reduced brush life. If you notice a loss in power or if the motor becomes excessively noisy, inspect the brushes. If the brushes are worn down to 1 4'' (6mm) or less, it is time to replace them. When checking brushes, be sure to return each brush to the same hole in the same direction that it came from. When replacing old brushes, replace both brushes at the same time. Tools Needed: Qty Hex Wrench 3mm... 1 Standard Screwdriver # To inspect and replace the motor brushes: Brush Cap Figure 59. Removing brush cap. 4. Remove the old brush assembly. If the brush is worn down to less than 1 4'' (6mm) then replace it with a new one. Otherwise re-install the brush (Figure 60). 1. DISCONNECT MILL/DRILL FROM POWER! 2. Un-install the motor cover by removing the four cap screws that secure it (Figure 58). Motor Cover Brush Assembly Figure 60. Installing new brush assembly. Cap Screw (1 of 4) Figure 58. Removing motor cover. 5. Replace the brush cap to secure the brush in place. 6. Repeat for second brush assembly on the other side of the motor. Model G0704 (Mfd. Since 04/13) -43-

60 machine SECTION 8: WIRING These pages are current at the time of printing. However, in the spirit of improvement, we may make changes to the electrical systems of future machines. Compare the manufacture date of your machine to the one stated in this manual, and study this section carefully. If there are differences between your machine and what is shown in this section, call Technical Support at (570) for assistance BEFORE making any changes to the wiring on your machine. An updated wiring diagram may be available. Note: Please gather the serial number and manufacture date of your machine before calling. This information can be found on the main machine label. Wiring Safety Instructions SHOCK HAZARD. Working on wiring that is connected to a power source is extremely dangerous. Touching electrified parts will result in personal injury including but not limited to severe burns, electrocution, or death. Disconnect the power from the machine before servicing electrical components! MODIFICATIONS. Modifying the wiring beyond what is shown in the diagram may lead to unpredictable results, including serious injury or fire. This includes the installation of unapproved aftermarket parts. WIRE CONNECTIONS. All connections must be tight to prevent wires from loosening during machine operation. Double-check all wires disconnected or connected during any wiring task to ensure tight connections. WIRE/COMPONENT DAMAGE. Damaged wires or components increase the risk of serious personal injury, fire, or machine damage. If you notice that any wires or components are damaged while performing a wiring task, replace those wires or components. MOTOR WIRING. The motor wiring shown in these diagrams is current at the time of printing but may not match your machine. If you find this to be the case, use the wiring diagram inside the motor junction box. CAPACITORS/INVERTERS. Some capacitors and power inverters store an electrical charge for up to 10 minutes after being disconnected from the power source. To reduce the risk of being shocked, wait at least this long before working on capacitors. CIRCUIT REQUIREMENTS. You MUST follow the requirements at the beginning of this manual when connecting your machine to a power source. EXPERIENCING DIFFICULTIES. If you are experiencing difficulties understanding the information included in this section, contact our Technical Support at (570) The photos and diagrams included in this section are best viewed in color. You can view these pages in color at Model G0704 (Mfd. Since 04/13)

61 Wiring Diagram P3 P1 P2 A+ See Figure 61 Circuit Board JD-014 5WR02J A Fuse F10AL250V 10A L1 L2 Fuse F15AL250V 15A Neutral Hot Ground See Figure 62 Chip Guard Limit Switch 110 VAC 5-15 Plug Spindle RPM Sensor B A IN N See IN Figure 64 Circuit Board CESX N1 G L1 Gnd Motor Brushes L 110V Motor RPM Display ZD-SX-THL Gnd A On/Off Switch Kedu KJD-178/120V Spindle Direction Knob Kedu EN61058 Spindle Speed Knob WX14-12 See Figure 63 Model G0704 (Mfd. Since 04/13) READ ELECTRICAL SAFETY ON PAGE 44! -45-

62 Electrical Components Figure 61. Rear panel. Figure 63. Control panel wiring. Figure 62. Chip guard limit switch. Figure 64. Side panel READ ELECTRICAL SAFETY Model G0704 (Mfd. Since 04/13) ON PAGE 44!

63 SECTION 9: PARTS Column Breakdown Model G0704 (Mfd. Since 04/13) -47-

64 Column Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 1 P Z-AXIS SLIDE 41 P Z-AXIS HANDWHEEL HANDLE M6-1 X 10 2 P SET SCREW M6-1 X P BALL BEARING 6001ZZ 3 P FLAT WASHER 8MM 43 P Z-AXIS HANDWHEEL SHAFT 4 P LOCK WASHER 8MM 44 P KEY 4 X 4 X 12 5 P CAP SCREW M X P PILLOW BLOCK 6 P FLAT WASHER 12MM 46 P SPACER 7 P LOCK WASHER 12MM 47 P PINION GEAR 8 P CAP SCREW M X P COLUMN 9 P T-BOLT M P Z-AXIS SCALE 10 P FLAT WASHER 10MM 50 P THREADED SLEEVE M6-1 X P LOCK WASHER 10MM 51 P CAP SCREW M6-1 X P HEX NUT M P X-AXIS LEADSCREW BRACKET (LH) 13 P SLIDE ALIGNMENT BLOCK 54 P TABLE 14 P BRASS PIN 55 P COOLANT HOSE FITTING 15 P ADJUSTABLE HANDLE M6-1 X P X-AXIS LEADSCREW BRACKET (RH) 16 P GIB ADJUSTMENT SCREW 57 P TABLE HANDWHEEL HANDLE M6-1 X P Z-AXIS GIB 58 P TABLE HANDWHEEL 18 P HEADSTOCK ANGLE SCALE 59 P TABLE GRADUATED DIAL 19 P CAP SCREW M5-.8 X P THRUST BEARING P Z-AXIS WAY COVER 61 P CAP SCREW M6-1 X P HEX NUT M P LIMIT STOP 22 P Z-AXIS WAY COVER BRACKET 63 P T-NUT M P Y-AXIS WAY COVER 64 P X-AXIS SCALE 24 P Y-AXIS WAY COVER BRACKET 65 P X-AXIS LEADSCREW 25 P LEADSCREW LOCK NUT M P X-AXIS LEADSCREW NUT 26 P THRUST BEARING P CAP SCREW M4-.7 X P RING GEAR 68 P SADDLE 28 P KEY 4 X 4 X P TABLE STOP BLOCK 29 P Z-AXIS LEADSCREW 70 P Y-AXIS GIB 30 P Z-AXIS LEADSCREW NUT 71 P Y-AXIS LEADSCREW NUT 31 P CAP SCREW M5-.8 X P X-AXIS GIB 31-1 P FLAT WASHER 5MM 73 P CAP SCREW M6-1 X P BEARING COVER 74 P X-AXIS BEARING HOUSING 33 P CAP SCREW M X P Y-AXIS LEADSCREW 34 P COLUMN TOP PLATE 76 P BASE 35 P COLLAR FLANGE 77 P CAP SCREW M X P CAP SCREW M5-.8 X P STAND ASSEMBLY 37 P Z-AXIS GRADUATED DIAL P STAND CABINET 38 P Z-AXIS HANDWHEEL P STAND DOOR 39 P HANDWHEEL CURVED PLATE SPRING P STAND DOOR LATCH 40 P HEX NUT M Model G0704 (Mfd. Since 04/13)

65 Electrical Box Breakdown & Parts List 92V REF PART # DESCRIPTION REF PART # DESCRIPTION 78 P CIRCUIT BOARD JD-014 5WR02J 87 P RPM DIGITIAL DISPLAY ZD-SX-THL 79 P SPINDLE SPEED KNOB WX P ELECTRICAL BOX 79-1 P SPINDLE SPEED POTENTIOMETER 89 P CAP SCREW M5-.8 X 8 80 P CAP SCREW M3-.5 X P ELECTRICAL BOX REAR COVER 80-1 P HEX NUT M P FUSE HOLDER 81 P CIRCUIT BOARD CESX V2 P V2 FUSE F15AL250V 15A V P ON/OFF SWITCH KEDU KJD-178/120V 93 P POWER CORD 16G 3W 72" P CAP SCREW M4-.7 X P STRAIN RELIEF M20 X 1.5 TYPE-3 85 P CONTROL PANEL PLATE 95 P FWD/REV SWITCH KEDU EN P CAP SCREW M4-.7 X 6 96 P FUSE F10AL250V 10A Model G0704 (Mfd. Since 04/13) -49-

66 Headstock Breakdown V V V V V Model G0704 (Mfd. Since 04/13)

67 Headstock Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 201 P QUILL RETAINING CLIP 238 P MILL HEAD CASTING 202 P BUSHING 239 P COVER PLATE 203 P COMPRESSION SPRING 240 P CAP SCREW M4-.7 X P EXT RETAINING RING 45MM 241 P FINE FEED KNOB 205 P BALL BEARING 6209ZZ 242 P FRONT COVER 206 P COMBO GEAR 60/70T 243 P HANDWHEEL CURVED PLATE SPRING P SPINDLE RING 16MM 244 P FINE FEED COLLAR P CAP SCREW M3-.5 X P WORM SHAFT 207 P BALL BEARING RS 246V2 P SPINDLE V P EXT RETAINING RING 15MM P DRAWBAR 209 P GEAR 37T 15MM ID BORE P RETAINER CUP P GEAR GUARD 247 P SPINDLE RING P CAP SCREW M3-.5 X P TAPERED ROLLER BEARING P EXT RETAINING RING 32MM 249 P QUILL SLEEVE 211 P BALL BEARING 6002ZZ 250 P RUBBER RING 212 P COMBO GEAR 42/62T 251 P ADJUSTER NUT 213 P SHAFT 252 P ADJUSTER NUT SCREW 214 P KEY 5 X 5 X P PIN 6 X P KEY 5 X 5 X P HANDLE 216 P FORK P HANDLE GRIP 217 P FORK ARM 256 P SELECTOR KNOB 218 P SET SCREW M5-.8 X P DOWNFEED HUB 219 P DRAWBAR CAP 258 P DOWNFEED COLLAR 220 P MOTOR COVER V1 259 P COMPRESSION SPRING 221V3 P V3 MOTOR 1HP 110V (14MM SHAFT) V P CAP SCREW M4-.7 X V2 P V2 CARBON BRUSH 1-PC V P DOWNFEED FLANGE 221-2V2 P V2 CARBON BRUSH CAP 1-PC V P SPACER 222 P FLAT WASHER 4MM 263 P WORM GEAR 223 P CAP SCREW M4-.7 X P KEY 4 X 4 X P CAP SCREW M6-1 X P GEAR SHAFT 225 P SENSOR BRACKET 266 P RIVET P SENSOR CORD 267 P HIGH/LOW ARROW PLATE P CAP SCREW M3-.5 X P SET SCREW M X P RPM SENSOR 269 P COMPRESSION SPRING 227 P MOTOR PLATE 270 P STEEL BALL 6.5MM 228 P CAP SCREW M5-.8 X P SPEED SELECTOR KNOB 229V2 P V2 EXT RETAINING RING 14MM 272 P SET SCREW M5-.8 X V2 P V2 GEAR 20T (ID 14MM) V P SPEED KNOB PLATE 231V2 P V2 KEY 5 X 5 X P FORK SHAFT FLANGE 232 P SET SCREW M5-.8 X P FORK SHAFT 233 P CAP SCREW M3-.5 X P CAP SCREW M3-.5 X P DIGITAL READOUT UNIT 292 P SPINDLE PIN P DIGITAL READOUT BRACKET 293 P ARBOR R8 X B P CAP SCREW M4-.7 X P DRILL CHUCK B MM 235 P BASE BLOCK 295 P CHUCK KEY FOR B16 16MM CHUCK 236 P QUILL LOCKING LEVER 296 P TAPERED ROLLER BEARING P BRASS PIN Model G0704 (Mfd. Since 04/13) -51-

68 Chip Guard Breakdown & Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 277 P FLAT WASHER 3MM 284 P GUARD LIMIT SWITCH 278 P HEX NUT M P PROTECTIVE PAPER 279 P CAP SCREW M4-.7 X P SET SCREW M5-.8 X P EXT RETAINING RING 12MM 287 P CHIP GUARD POST 281 P WAVY WASHER 20MM 288 P CHIP GUARD 282 P GUARD MOUNTING BLOCK 289 P CAP SCREW M4-.7 X P COPPER SPACER -52- Model G0704 (Mfd. Since 04/13)

69 Labels Breakdown & Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 301 P READ MANUAL LABEL 306 P MODEL NUMBER LABEL 302 P SAFETY GLASSES LABEL 307 P GREEN TOUCH-UP PAINT 303 P MACHINE ID LABEL 308 P CUTTER WARNING LABEL 304 P HIGH/LOW SPEED LABEL 309 P ENTANGLEMENT LABEL 305 P PUTTY TOUCH-UP PAINT 310 P AVOID OVERHEATING NOTICE Safety labels warn about machine hazards and ways to prevent injury. The owner of this machine MUST maintain the original location and readability of the labels on the machine. If any label is removed or becomes unreadable, REPLACE that label before using the machine again. Contact Grizzly at (800) or to order new labels. Model G0704 (Mfd. Since 04/13) -53-